Vehicle sunroof with weatherstrip mounting flange

Abstract

A sunroof panel structure for substantially closing a sunroof aperture in a vehicle. The sunroof panel structure includes a sunroof panel member having a plurality of edges and a weatherstrip mounting flange. The weatherstrip mounting flange and the sunroof panel member are unitarily formed such that the weatherstrip mounting flange is coupled to at least one of the plurality of edges. The weatherstrip mounting flange is configured to receive a weatherstrip seal member without the use of adhesives or other bonding agents or mechanisms. A method for forming a sunroof assembly for an automotive vehicle is also provided.

What is claimed is:  
     
       1. A one-piece sunroof panel structure for substantially closing a sunroof aperture in a vehicle, the sunroof panel structure comprising a sunroof panel member and a weatherstrip mounting flange, the sunroof panel member having an outer surface, which is adapted to form a portion of an exterior surface of the automotive vehicle, an inner surface disposed opposite the outer surface, and a plurality of edges, the weatherstrip mounting flange being formed in one piece with the panel member along at least one of the plurality of edges and including a pair of spaced-apart furcations that cooperate to form a weatherstrip groove therebetween, each of the furcations being arranged generally parallel to said outer surface, a first one of the furcations terminating on a side opposite the weatherstrip groove in a second plane that is generally coincident with the outer surface of the sunroof panel. 
     
     
       2. The sunroof panel structure of claim  1 , wherein a second one of the furcations is spaced apart from the inner surface of the sunroof panel. 
     
     
       3. The sunroof panel structure of claim  2 , wherein the weatherstrip mounting flange further includes a gusset coupled to the second one of the furcations and the sunroof panel. 
     
     
       4. The sunroof panel structure of claim  1 , wherein at least one of the furcations includes a barb structure that is adapted to engaging a weatherstrip seal and inhibiting the weatherstrip seal from being withdrawn from the weatherstrip mounting flange. 
     
     
       5. The sunroof panel structure of claim  4 , wherein the barb structure includes a tapered nose portion. 
     
     
       6. The sunroof panel structure of claim  1 , wherein the sunroof panel member is formed from plastic. 
     
     
       7. The sunroof panel structure of claim  6 , wherein the sunroof panel member is formed from a plastic composite, the plastic composite having a film member and a plastic substrate member. 
     
     
       8. The sunroof panel structure of claim  7 , wherein the film member is resistant to scratching and degradation from ultra-violet radiation. 
     
     
       9. A sunroof assembly for an automotive vehicle having a vehicle body that defines a sunroof aperture, the sunroof assembly comprising: 
       a one-piece sunroof panel structure having a sunroof panel member and a weatherstrip mounting flange, the sunroof panel member having an outer surface, which is adapted to form a portion of an exterior surface of the automotive vehicle, an inner surface disposed opposite the outer surface, and a plurality of edges, the weatherstrip mounting flange formed along at least one of the plurality of edges and including a pair of spaced-apart furcations and a gusset, the furcations cooperating to form a weatherstrip groove therebetween, each of the furcations being arranged generally parallel to said outer surface, a first one of the furcations being spaced apart from the inner surface of the sunroof panel, the gusset being coupled to the first one of the furcations and the sunroof panel such that the weatherstrip mounting flange is relatively thicker than the sunroof panel; and  
       a weatherstrip seal coupled to the weatherstrip mounting flange, the weatherstrip seal having a wall member that is disposed in the weatherstrip groove.  
     
     
       10. The sunroof assembly of claim  9 , wherein at least one of the furcations includes a barb structure for engaging the weatherstrip seal and inhibiting the weatherstrip seal from being withdrawn from the weatherstrip mounting flange. 
     
     
       11. The sunroof assembly of claim  10 , wherein the barb structure includes a tapered nose portion. 
     
     
       12. The sunroof assembly of claim  9 , wherein the sunroof panel member is formed from plastic. 
     
     
       13. The sunroof assembly of claim  12 , wherein the sunroof panel member is formed from a plastic composite, the plastic composite having a film member and a plastic substrate member. 
     
     
       14. The sunroof assembly of claim  13 , wherein the film member is resistant to scratching and degradation from ultra-violet radiation. 
     
     
       15. A sunroof assembly for an automotive vehicle having a vehicle body that defines a sunroof aperture, the sunroof assembly comprising: 
       a one-piece sunroof panel structure having a sunroof panel member and a weatherstrip mounting flange, the sunroof panel member having an outer surface, which is adapted to form a portion of an exterior surface of the automotive vehicle, an inner surface disposed opposite the outer surface, and a plurality of edges, the weatherstrip mounting flange formed along at least one of the plurality of edges and including a pair of spaced-apart furcations that cooperate to form a weatherstrip groove therebetween, each of the furcations being arranged generally parallel to said outer surface, a first one of the furcations terminating on a side opposite the weatherstrip groove in a second plane that is generally coincident with the outer surface of the sunroof panel; and  
       a weatherstrip seal coupled to the weatherstrip mounting flange, the weatherstrip seal having a wall member that is disposed in the weatherstrip groove.  
     
     
       16. The sunroof assembly of claim  15 , wherein a second one of the furcations is spaced apart from the inner surface of the sunroof panel. 
     
     
       17. The sunroof assembly of claim  16 , wherein the weatherstrip mounting flange further includes a gusset coupled to the second one of the furcations and the sunroof panel. 
     
     
       18. The sunroof assembly of claim  15 , wherein at least one of the furcations includes a barb structure for engaging the weatherstrip seal and inhibiting the weatherstrip seal from being withdrawn from the weatherstrip mounting flange. 
     
     
       19. The sunroof assembly of claim  18 , wherein the barb structure includes a tapered nose portion. 
     
     
       20. The sunroof assembly of claim  15 , wherein the sunroof panel member is formed from a plastic composite, the plastic composite having a film member and a plastic substrate member.